of 40 /40
Ground Systems Integration Domain (GSID) Materials for Ground Platforms 20 SEP 2010 Ms. Lisa Prokurat Franks Materials Engineer Office of the Chief Scientist UNCLASSIFIED: DIST A. APPROVED FOR PUBLIC RELEASE UNCLASSIFIED: DIST A. APPROVED FOR PUBLIC RELEASE

Ground Systems Integration Domain (GSID) Materials for ... · us army rdecom-tardec 6501 e 11 mile rd warren, mi 48397-5000, usa 8. performing organization report number 21199rc 9

  • Author
    others

  • View
    0

  • Download
    0

Embed Size (px)

Text of Ground Systems Integration Domain (GSID) Materials for ... · us army rdecom-tardec 6501 e 11 mile...

  • Ground Systems Integration Domain (GSID) Materials for Ground Platforms

    20 SEP 2010

    Ms. Lisa Prokurat FranksMaterials EngineerOffice of the Chief Scientist

    UNCLASSIFIED: DIST A. APPROVED FOR PUBLIC RELEASE

    UNCLASSIFIED: DIST A. APPROVED FOR PUBLIC RELEASE

  • Report Documentation Page Form ApprovedOMB No. 0704-0188Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering andmaintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information,including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, ArlingtonVA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if itdoes not display a currently valid OMB control number.

    1. REPORT DATE 20 SEP 2010

    2. REPORT TYPE N/A

    3. DATES COVERED -

    4. TITLE AND SUBTITLE Ground Systems Integration Domain (GSID) Materials for Ground Platforms

    5a. CONTRACT NUMBER

    5b. GRANT NUMBER

    5c. PROGRAM ELEMENT NUMBER

    6. AUTHOR(S) Lisa Prokurat Franks

    5d. PROJECT NUMBER

    5e. TASK NUMBER

    5f. WORK UNIT NUMBER

    7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) US Army RDECOM-TARDEC 6501 E 11 Mile Rd Warren, MI48397-5000, USA

    8. PERFORMING ORGANIZATION REPORT NUMBER 21199RC

    9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) US Army RDECOM-TARDEC 6501 E 11 Mile Rd Warren, MI48397-5000, USA

    10. SPONSOR/MONITOR’S ACRONYM(S) TACOM/TARDEC

    11. SPONSOR/MONITOR’S REPORT NUMBER(S) 21199RC

    12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release, distribution unlimited

    13. SUPPLEMENTARY NOTES The original document contains color images.

    14. ABSTRACT

    15. SUBJECT TERMS

    16. SECURITY CLASSIFICATION OF: 17. LIMITATIONOF ABSTRACT

    SAR

    18. NUMBEROF PAGES

    39

    19a. NAME OFRESPONSIBLE PERSON

    a. REPORT unclassified

    b. ABSTRACT unclassified

    c. THIS PAGE unclassified

    Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

  • Tank Automotive Research, Development & Engineering CenterDr. Grace Bochenek, Director

    Overview

    Distribution approved for Public Release; distribution Unlimited, per AR 380-5. OPSEC Review conducted per AR 530-1 and HQ TACOM OPSEC SOP #20587

  • Responsible for Research, Development and Engineering Support to 2,800 Army systems and many of the Army’s and DOD’s Top Joint Warfighter Development Programs

    Mission

    Ground Systems Integratorfor the Department of Defense

    – Provides full life-cycle engineering support and is provider-of-first-choice for all DOD ground combat and combat support vehicle systems.

    – Develops and integrates the right technology solutions to improve Current Force effectiveness and provide superior capabilities for the Future Force.

    Unclassified 2

  • Army

    Materiel

    Command

    (AMC)

    TACOM

    LCMC

    (ASA(ALT))

    ILSC

    ACQ

    Center

    Industrial

    Base

    PEO

    GCS

    PEO

    CS&CSS

    PEO

    Soldier

    PEO Integration

    Department of

    the Army (DA)

    Armament Research, Development and Engineering Center (ARDEC)

    Army Research Laboratory (ARL)

    Edgewood Chemical and Biological Center (ECBC)

    Aviation and Missile Research, Development and Engineering

    Center (AMRDEC)

    Natick Soldier Research, Development and Engineering Center

    (NSRDEC)

    Communications-Electronic Research, Development and Engineering Center

    (CERDEC)

    Simulation and Training Technology Center (STTC)

    Research, Development and Engineering Command

    (RDECOM)

    3Unclassified

    Organizational Relationships

    Army Materiel Systems Analysis Activity (AMSAA)

    Reach back to over 8,500 Scientists and Engineers

  • Senior Research Scientist - Robotics

    Organizational Structure

    4Unclassified

    TARDEC Director

    Chief ScientistExecutive Director

    of Engineering

    Systems Engineering

    Life-Cycle Data Management

    RAM, Test & QualityAssurance

    Standardization &Transportability

    Software Engineering Center

    Industrial Base Engineering Support

    Executive Director ofProduct Development

    Center for Ground Vehicle Development

    & Integration

    Force Projection Technology

    National AutomotiveCenter (NAC)

    Executive Director of Research & Technology

    Integration

    Concepts, Analysis,Systems, Simulations

    & Integrations (CASSI)

    Ground SystemsSurvivability

    Intelligent Ground Systems

    Ground Vehicle Power & Mobility

    Joint Center for Robotics

    Vehicle Electronics & Architecture

    Military Deputy

    Chief of Staff

    Foreign Vehicle Specs & Materials Eng

    Eng – Systems in Acquisition

  • Combat Vehicles • Heavy Brigade Combat Team• Strykers• MRAPs• Ground Combat Vehicles (Future)

    Tactical Vehicles• HMMWVs • Trailers• Heavy, Medium and Light

    Tactical Vehicles

    Force Projection• Fuel & Water Distribution • Force Sustainment • Construction Equipment • Bridging • Assured Mobility Systems

    Robotics• Technology Components• Demonstrators• Military Relevant Test & Experimentation• Transition & Requirements Development

    5Unclassified

    Portfolio

    TARDEC Engineers Provide Cradle-To-Grave Engineering Support

  • System & Simulation Integration Laboratories

    Laboratory Capabilities

    Grease & Hydraulic Fluid Lab

    Fuels & Lubricants Laboratories

    Coolant Lab Fuel & Lube Lab Analytical Lab

    Physical Simulation Laboratories

    Vehicle Inertial Properties Evaluation Rig

    Reconfigurable N-Post Simulator Multi-Axial Simulator

    Survivability Laboratories

    Ballistic Testing

    Center for Ground Vehicle Development & Integration

    Large Robotics Integration Cell

    Prototype Integration

    Ground Systems Power & Energy Lab

    Propulsion Laboratories

    6

    Power & Energy Laboratories

    Unclassified

    TARDEC’s Warren, MI operations has a resource value of over $950M and occupies 12 facilities on the Detroit Garrison totaling over 840,000 square feet of laboratory space

    Concept Development Modeling & Simulation Environment

    System Evaluation MRAP Systems Integration Lab

  • Material Initiatives and Needs for Lightening Ground Platforms

    11 March 2010

    Dr. Douglas TempletonUS Army TARDEC

    UNCLASSIFIED: Dist A. Approved for public release

  • Motivation

    • Lightweight/Mobile

    • Threat Designable/Repairability

    • Armor: Multifunctional Ballistic/Structural/Stealth

    DRIVERS

    PERFORMANCE

    PROTECTION PAYLOAD

    NEED TO BALANCE

    The 3 Ps!

    UNCLASSIFIED

  • Importance of Basic & Applied Research

    Brittle Materials:• Material properties• Processing/synthesis• Ceramic optimization• Failure mechanisms • Failure morphology• Dynamic behavior modeling• Laboratory characterization techniques

    · Determination of properties relevant to ballistic impact

    Mechanics of Composites

    - Finite element codes

    - Strength of materials

    - Analysis of thick composites

    - Micro scale model

    Penetration Mechanics:

    - Constitutive material models

    - Hi-strain rate propagation

    - Metallurgy

    - Hydrocode development

    Armor Mechanics:•-Defeat Mechanism• Encapsulation Techniques• Ceramic Optimization• Multi-hit• Structural Response• Ballistic Shock• Modeling• Trends analyses· Armor optimization· Initial trades studies/analyses

    Structural Design Tech:• Design trades• LW structural Response

    Structure• Load optimization• Attachment design• Shock/vibration• Damage tolerance• Affordability• RAM

    Platform integration,

    producibility, and

    performance testing

    Basic Research

    Applied Research

    Adv Development

    Eng Development

    INITIATION

    IOC

    Basic research critical to success, and must be a CONTINUING activity

    Armor module dev/fab• Robustness • Manufacturability• Attachment design• Shock transmission• Affordability• RAM

    Trades analyses • Performance• Weight• Cost

    UNCLASSIFIED

  • Materials for Ground Platforms

    –Ideal situation: materials readily available and fully developed.

    • RHA

    • High hard steel

    • Aluminum

    –Reality: Research projects are ongoing to further develop advanced lightweight armors.

    • Composites

    • Ceramics

    • Titanium

    • Magnesium

    • Composite and

    metal matrix

    –Long Term Armor Strategy

    • A + B design

    • Requirements are classified

    UNCLASSIFIED

  • Design Drivers –Cost/Weight/Volume

    • Silicon Carbide Armor Tile Comparison at Equivalent Ballistic Protection

    • (production cost)

    • Titanium & Aluminum/Lithium Alloy Raw Material Cost

    ~$12/lb vs. ~$4/lb for Conventional Aluminum

    SiC

    Composite

    SiC

    Titanium TitaniumSpall Liner

    Alumina

    Titanium

    Spall Liner

    Alumina

    Composite

    20-23 psf$80/lb*1.0-1.5”

    20 psf$80/lb*1.65”

    40 psf$30/lb*1.75”

    30 psf$35/lb*2.15”

    30-33 psf$50/lb*1.5-2.0”

    UNCLASSIFIED

  • Structural Approaches

    • Space Frame

    –Lightest “structure only” weight

    –Tailorable survivability

    • Ballistic armor tailored to mission requirements

    • Low burden integration of other enhancements.

    –Ease of repair

    –Improved transportability

    MonocoqueSpace Frame

    MonocoqueLightest weight approach assuming a base level of ballistic protectionEfficient integrated structural armor solutionsMaximum interior volumeLowest cost

    Hybrid Structures

    UNCLASSIFIED

  • Combat Vehicles

    • Thick, heavy armor

    • Structure as by-product of armor

    • Inherently damage tolerant

    • Arrive on ships

    • Well understood materials and manufacturing practices

    • Designed for force-on-force engagement

    • Cumbersome logistics tail

    • Basic situational awareness

    • Lightweight armor

    • Structure plus armor (A + B)

    • Relatively damage intolerant

    • Air transportable (C-130)

    • Advanced ceramic armors, use of polymer composites and associated mfg. practices

    • Designed for noncontiguous, non-linear, reorganizing battlefield

    • Common components, reduction of logistics footprint

    • Network centric, highly interdependent

    Current Future

    UNCLASSIFIED

  • Issues to LightweightingCombat Vehicles

    • Development of survivable vehicle systems while keeping to air transport weight (aircraft dependent)

    • Attachment methodologies for A + B armor concept, appurtenances

    • Joining and fastening technologies (dissimilar materials), adhesives

    • Balancing interior volume against the use of less efficient structural material solutions

    • Signature management, electromagnetic shielding over potentially non-metallic surfaces

    • Diagnostics & prognostics for structural health assessment

    • Material costs and improving multi-hit performance

    • Advanced structures offer part consolidation necessitating development of high yield mfg. processes

    • Inspection and repair of advanced armor systems

    • Improved modeling and simulation

    Frame Assembly

    Composite Upper Skin

    Conceptual Designs

    Armor Module

    UNCLASSIFIED

  • Tactical Vehicles

    • Tired and aging fleet

    • Corrosion prone

    • Cabs typically unarmored. Armoring via add-on-armor kits

    • Reduced vehicle payload, maneuverability, reliability, safety, maintainability, and life expectancy

    – Increased wear and tear on vehicle components, fuel consumption, and life cycle costs

    • Multiple original equipment manufacturers, little commonality

    – Designed for traditional role of logistics support

    • Recapitalization with appliqué armor (A-kit/B-kit)

    • Be more survivable in mine blast events

    • Component commonality (hardware, transparent armor, B-kit panels

    • Gun turret and advanced countermeasures

    • Crew installable B-kit, with minimal tools

    • Enhanced crew survivability to meet threat

    • Increased system reliability

    • Taking on more of an assault role

    Current Future

    UNCLASSIFIED

  • Issues to lightweightingTactical Vehicles

    • Balancing material costs over a large vehicle fleet

    • Integration of hybrid, advanced materials, and layered armor solutions

    • A-frame with mounting points which allow for rapid addition/removal of B-kit, and spiral-in of emerging armor technologies

    • Addressing seams and edges that result from modular armor

    • Tile confinement for enhanced ceramic armor performance

    • Improving armor multi-hit performance of advanced armors

    • Opaque armors under 28 psf and transparent armors under 30 psf

    • Keeping transparent armor thickness to a minimum

    • Durability of advanced lightweight armors

    • Health assessment of advance armors

    • Improved modeling and simulation

    A-Kit/B Kit Concept

    UNCLASSIFIED

  • Validated Design and Analysis Tools

    • Quarter Section TestingFlexureShearIn-plane

    Experimental Database for

    FEA

    Database for Development and

    Validation of Laminate Modeling

    Develop analysis tools critical for structural design

    Sub-element Testing Required

    UNCLASSIFIED

  • SUMMARY Of Material Initiatives and Needs for

    Lightening Ground Platforms

    • Significant challenges remain in areas of material development

    • Need to look at not just basic materials but structural approaches

    • Modeling and simulation is a critical enabler

    UNCLASSIFIED

  • Ground Systems Integration Domain (GSID) Workshop on Materials for Ground Platforms

    University Center - Macomb Community College

    Clinton Township, MI

    August 23-24, 2010

    Unclassified

    Unclassified

  • Ground Systems Integration Domain(GSID)

    21

    Unclassified

  • Holistic Approach to Ground Combat Vehicle Platform Innovation

    RDECOM will rapidly develop platform designs and demonstrators driving innovation in the areas of ground platform survivability and mobility.

    Platform Weight Class Project PartnersProject Objectives

    • Novel, inventive vehicle design approaches• Rapid acquisition (12-18 month timelines)• Extensive use of M&S tools to optimize design• Non-tradition defense project partners

    • Embedded with ARCIC to drive requirements generation for future platform requirements

    Driving Innovation across the Ground Community:

    Project Schedule

    14,000 - 16,000 lbsLight Tactical

    • 30% Fuel Economy Improvement over M1151

    • Maintain Mobility of M1114

    • MRAP Threshold Survivability

  • Light TacticalOverarching Research Objectives

    Primary Research Objectives (Occupant-Centric Survivability Focused):

    1. 4500 lbs + trailer towing capacity; 4-6 man crew compartmentPayload

    2. 14,000 lb curb vehicle weightPerformance

    4. $250,000 base vehicle (@ 10K Qty)Price

    5. 12 monthsSchedule

    3. MRAP threshold survivability employing modular base armorProtection

    Secondary Research Objectives (Light Tactical Vehicle Key System Attributes):1. Select JLTV requirements as secondary research objectivesPerformance

    Double V-Shaped Hull

    HDX Modular Armor (Spall, A-Kit, B-Kit, C-Kit & RPG Defeat Interface)

    Virtual Transparent Armor

    SBC (Lightweight Blast Mitigation System)

    High-Energy Double Duty Lithium Ion Batteries

    Hybrid Electric Propulsion System

    Computer-controlled Magnetorheological (MR) Semi-Active Suspension

    Modular Drivetrain & Suspension

    Projected Cost:$20M

    Unclassified

  • Workshop Expectations

    • Research Driven Opportunities

    – 6.1, 6.2 -> What should the GSID follow and support?

    – Awareness and participation in Material Science Programs

    • Opportunities to integrate

    – Demonstrator programs (6.3)

    – Platform/Product/Part Driven Needs

    • PEO GCS, CS&CSS modernization programs

    • OEMs

    • DLA/Sustainment

    • Depots

    • Barriers to adoption of new materials?

    – Environment, safety, cost, weight, size, MRL/TRL

    Unclassified

  • From PEO CS&CSS (23AUG 2010)

    How to cross the “Valley of Death” transitioning a technology into an acquisition program

    • Most commonly from Army S&T (6.3 funded) TRL-6 to a Program of Record (6.4+)

    • Know the Technology Readiness Level (TRL) of your technology

    • Get to know the target platform

    – Where is the program in its lifecycle?

    • Determines the amount of each of the funding types available to the PM

    • Determines the maturity of the technology (TRL) the PM can accept (for example: TRL-6 at MS-B)

    – Technologies going into a POR undergo Technology Readiness Assessments (TRA)

    – What is the POR’s acquisition strategy – COTS or Developmental?

    – PMs must have a requirement, validated by TRADOC, to acquire technology

    • Understand the transition pathway – this is for you to have fully worked out

    – Does your technology have to be integrated in another manufacturer’s system?

    – Can you manufacture your technology in quantity?

    • Cost matters!

    TRL-4 TRL-6 TRL-7 TRL-8 TRL-9

    TRA TRA

    Unclassified

  • From PEO GCS (23AUG 2010)

    Overarching

    26

    • Review of the ongoing activities in RDECOM, DARPA, academia, industry, partnering, and structured analysis to identify best opportunities-Funnel thru GSID

    • Safety: During production through Hostile Engagement

    • Primary: Power, survivability, communications, lethality

    • Environmentally safe and nonhazardous

    • Reflect heat, absorb solar energy to power batteries, shock absorbing (external and internal)

    • EMI friendly so we can add antennas and retain low signatures

    • Repeated heat/cold cycles.

    Unclassified

  • From PEO GCS (23AUG 2010)

    Prioritized Capability Gaps

    Unclassified

  • From PEO GCS (23AUG 2010)

    -ilities for the Platforms

    • New survivability materials must have good durability to last until needed Synergetic effects of armor metallic (AL, STL, TI) laminated with ballistic liners (Kevlar, E-glass, S-glass....)

    • Reduced flammability: Don’t put polyethylene base composite inside the vehicle such as Dyneema, Tenselon, Spectra

    • Maintainability to allow field removal, replacement and/or repair: suitable chromium replacement

    • Compatibility to resist corrosion and/or fungus

    •Affordability with no negative impact on SWaP-C -lightweight structures

    • Materials for power electronics'–Suitable lead-free solder–Efficiency and increase operating temperature(i.e. SiC, magnetics)–Batteries to increase energy/power density(i.e. LiIon, energy dense cathodes )

    • Polymers for suspension and track

    • Lubricants: Single lube forward compatible with VHM Sensors

    Unclassified

  • PEO Material Property Needs

    • Strength

    • Lightweight

    • Manufacturable

    • Maintainable

    • Corrosion and fungus resistant

    • Environmentally friendly

    • Low-cost

    • Reduced flammability materials

    • Long life

    • End-of-life plan

    29

    Unclassified

  • PEO Needs - Specifics

    • Replacement for Cr

    • Lead free solder

    • Replacement for Halon

    • Polymers for suspension and track

    • Improved metals, glass, cloth

    • Energy storage materials

    • Bridging technologies – bridge, boat, trucks, health monitoring

    • Propulsion systems to burn JP8 without sacrificing sensors

    • Packaging for water and fuel

    • Single lube compatible with existing sensors

    30

    Unclassified

  • R&D Agencies Represented

    • ARDEC

    • ARL

    • ARL WMRD

    • ARO

    • DARPA

    • DOE-ORNL

    • DOE-PNNL

    • DOE-VTP

    • NIST

    • PEO CS&CSS

    • PEO GCS

    • TARDEC

    • USACE-ERDC

    31

    Unclassified

  • Lightweight materials

    • Metals, alloys– Advanced High Strength Steels – many varieties

    – Titanium – needs work to produce inexpensively

    – Magnesium

    – Structural amorphous metals

    • Non-Metals– Composites of every variety

    • Carbon fiber

    • Graphene

    • Glasses

    • Ceramics

    • Polymeric fibers

    – Boron carbide

    32

    Unclassified

  • Materials of the Future

    • Nanomaterials– Nano grain sizes

    – Carbon

    – Coatings

    • Bio-inspired materials

    • Structured architectures

    • Self-healing

    • Damage sensing elastomers

    • High-strength fibers

    • Armors that spread the energy

    • Foams, lattice materials

    • Chemical manipulation

    • Unprecedented properties

    • Multi-materials

    33

    Unclassified

  • • Army started UARCs why? nsf?

    • Schuh: work non-aqueous deposition

    • Biotechnology

    • Assumption: normal structures are ltwt;

    • Low energy cons?

    • How does DARPA see GSID helping itself? Ti initiative: structural amorphous metals (SAMS)

    • Where is basic material science incubating? Universities: National labs?

    • Controlling microstructure?

    • Establish property – architectural specs?

    • What is the process to bring new ideas and materials to the PMs, PEOs, etc?

    • How does the basic research translate to useable materials?

    • 61., 6.2, 6.3 appear to be stove piped: how to fix?

    Unclassified

  • Workshop Expectations

    • Research Driven Opportunities– 6.1, 6.2 -> What should the GSID follow and support?

    – Awareness and participation in Material Science Programs

    • Opportunities to integrate– Demonstrator programs (6.3)

    – Platform/Product/Part Driven Needs

    • PEO GCS, CS&CSS modernization programs

    • OEMs

    • DLA/Sustainment

    • Depots

    • Barriers to adoption of new materials?– Environment, safety, cost, weight, size, MRL/TRL

    • It is a Workshop

    Unclassified

  • GSID Expectations

    • Opportunities– 6.2, 6.3

    – PEO GCS, CS&CSS

    – OEM

    • Why do we have the heaviest SLAT armor?

    Unclassified

  • Needs

    • Stronger, lighterweight

    • High energy storage devices

    • Better processing– Lower cost manufacture methods

    – New technology forming methods

    – Joining – welding

    • Models and Simulations– Understand structures

    – Predict materials and properties

    • Testing– NDE

    – Accelerated corrosion testing

    – Available standards

    – Standardized test methods 37Unclassified

  • Greatest Need

    • A guide to traverse the Valley of Death

    – Requirements understood by researchers

    – Complete technical specs for new materials transferred to PEOs

    38

    Unclassified

  • 39

    GSID Materials Workshop

    Review of Issues/Actions from Day 1

    • Both PEO’s have commonality and SWAP-C needs• Create GSID/PEO Integration Guide• Avoiding the “Valley of Death” Guide• Road mapping meetings?• PEO TRA Support?• Why is Value Engineering so Hard?• Lightweight track ROI business case – share?• Titanium path forward with DARPA• P&E materials work skipped?• Dan Morse – low temperature semiconductors• Dr. Prater – materials by design• Xtalic – quick win?• Reversible damage sensing elastomer – Q-win?• Tortorelli: CF8C – Plus steel – Cat – Q-win?• What are transition issues to carbon fiber?• Leveraging vehicle light weighting efforts

    Unclassified